Flexible Display with Preformed Curvilinear Foldable Substrate and Corresponding Electronic Devices and Methods

1. A flexible display comprising a foldable display coupled to a foldable layer, the foldable layer preformed to maintain a curvilinear three-dimensional shape when in a neutral, force-free state, wherein the foldable layer comprises a stainless steel foldable layer.

2. The flexible display of claim 1, further comprising an electronic device housing pivotable between an axially displaced open position and a closed position and coupled to the flexible display, the curvilinear three-dimensional shape simulating one or more contours of the electronic device housing.

3. The flexible display of claim 2, the electronic device housing comprising a first device housing coupled by a hinge to a second device housing.

5. The method of claim 4, the preforming and the coupling occurring simultaneously.

6. The method of claim 5, the preforming and the coupling occurring about a forming tool.

7. The method of claim 6, the forming tool comprising a mandrel.

8. The method of claim 4, the electronic device housing comprising a first device housing and a second device housing, the one or more contours defined by interior surfaces of one or both of the first device housing or the second device housing when at least partially folded about a hinge coupling the first device housing to the second device housing.

9. The method of claim 8, the partially folded shape comprising at least one convex contour and at least one concave contour.

11. The electronic device of claim 10, the flexible display further comprising a first adhesive layer coupled between the foldable display and the foldable substrate.

12. The electronic device of claim 11, the flexible display further comprising a foldable cover layer coupled to the foldable display by a second adhesive layer, with the foldable display disposed between the first adhesive layer and the second adhesive layer.

13. The electronic device of claim 12, the predefined curvilinear three-dimensional shape of the foldable substrate retaining the foldable display in the predefined curvilinear three-dimensional shape when in a neutral, force-free state.

14. The electronic device of claim 10, the electronic device housing comprising a first device housing coupled to a second device housing by a hinge, the predefined curvilinear three-dimensional shape simulating one or more contours of an interior of one or both of the first device housing or the second device housing when the first device housing is at least partially pivoted about the hinge relative to the second device housing to the closed position.

15. The electronic device of claim 14, the flexible display transitioning through a partially folded shape as the first device housing pivots about the hinge from an axially displaced open position to a closed position, wherein the foldable substrate is preformed to maintain the partially folded shape when in a neutral, force-free state.

16. The electronic device of claim 14, the foldable substrate deflecting from the predefined curvilinear three-dimensional shape to a substantially planar shape when the first device housing pivots about the hinge to the axially displaced open position.

17. The electronic device of claim 16, the foldable substrate deflecting from the predefined curvilinear three-dimensional shape to a fully folded shape when the first device housing pivots about the hinge to the closed position.

18. The electronic device of claim 17, the fully folded shape defining at least one convex contour with a first radius, the partially folded shape defining the at least one convex contour with a second radius that is greater than the first radius.

19. The electronic device of claim 18, the fully folded shape defining at least one concave contour with a third radius, the partially folded shape defining the at least one concave contour with a fourth radius that is greater than the third radius.